NEW MANUFACTURING CHALLENGE

HOUSEKEEPING & WORKPLACE ORGANISATION ARE DIRECTLY LINKED TO ACHIEVING DISCIPLINE IN MANUFACTURING

ONLY WHEN HOUSEKEEPING AND WORKPLACE ORGANISATION ARE CO-ORDINATED, WE CAN PROCEED FURTHER IN OUR PURSUIT OF EXCELLENCE IN MANUFACTURING

WORKPLACE ORGANIZATION

JUST AS WE TAKE A BATH OR SHOWER TO WASH OFF THE DIRT AND SWEAT, OUR FACTORY AND WORKPLACE ALSO NEEDS TO TAKE ATHROUGH CLEANSING PERIODICALLY IN ORDER TO GET RID OF ACCUMULATED WASTES.

5-S, THE JAPANESE APPROACH

IN JAPAN, 5 S WHICH STANDS FOR GOOD HOUSEKEEPING CONCEPTS IS CONSIDERED THE BASIS FOR CONTINUOUS PRODUCTIVITY AND QUALITY IMPROVEMENTS.

WHAT IS 5 S ?
1. SEIRI : SORT OUT UNNECESSARY ITEMS IN THE WORKPLACE AND DISCARD THE SAME.

2. SEITON : ARRANGE NECESSARY ITEMS IN GOOD ORDER SO THAT THEY CAN BE EASILY PICKED FOR USE. * A PLACE FOR EVERYTHING * EVERYTHING IN PLACE 3. SEISO : CLEAN YOUR WORKPLACE COMPLETELY SO THAT THERE IS NO DUST ON THE FLOOR, MACHINES, AND EQUIPMENT. 4.SEIKETSU:MAINTAIN HIGH STANDARD OF HOUSEKEEPING DISCIPLINES AUTONOMOUSLY 5. SHITSUKE : TRAIN PEOPLE TO FOLLOW GOOD HOUSEKEEPING DISCIPLINES AUTONOMOUSLY.

IMPORTANCE OF 5 S
A CLEAN WORKPLACE IS HIGH IN PRODUCTIVITY A CLEAN WORKPLACE HAS HIGH QUALITY A CLEAN WORKPLACE KEEPS DOWN COST A CLEAN WORKPLACE ENSURES ON TIME DELIVERY A CLEAN WORKPLACE ENSURES SAFETY A CLEAN WORKPLACE IS HIGH IN MORALE

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WHAT CAN WE GAIN FROM 5 S

# 5 S MAKES ONES WORKPLACE MORE PLEASANT

# 5 S HELPS IN WORK EFFICIENCY

# 5 S AND SAFETY GO HAND-IN- HAND

# 5 S LEADS TO BETTER QUALITY PRODUCTS AND HIGHER PRODUCTIVITY.

HOW DO WE PRACTISE SEIRI ?

STEP 1 * LOOK AROUND * DO THIS THINGS BELONG TO ME? * ARE THEY OF USE ANYMORE? THROW AWAY THESE IMMEDIATELY

(Sort out unnecessary items in the workplace and discard them)

STEP 2 * ARE THERE THINGS WHICH BELONG TO OTHER PEOPLE OR TO THE COMPANY? * ARE THEY NECESSARY OR UNNECESSARY? * PASTE A DISPOSAL NOTICE ON THE OBJECT WHICH SEEM UNNECESSARY. STEP 3 * AT THE END OF THE STATED PERIOD(VIDE DISPOSAL NOTICE), CHECK IT TO SEE IF ANYONE HAS REPLIED AND ACT ACCORDINGLY.

DISPOSAL NOTICE
Inspectors Name Description of Item Date Posted Please reply by : : : : 5S facilitator Inspector to describe them accurately. This is necessary to determine the period for consideration Deadline for reply

Description : The owner should confirm or correct the description given by the inspector Status : e.g. detect item, awaiting delivery. Disposal plan : e.g. to throw away,relocate,deliver to customer, send to warehouse. Date for disposal action to be stated. Owners Name : Section leader, Supervisor, Manager. Date : Date of reply

HOW DO WE PRACTISE SEITON ?

STEP 1
* Look at the way things are arranged in your workplace. * Are the things properly arranged (according to a certain system)? * Are they left all over the place? * Remember everything should be in its place. * Draw up a plan on location of things.

STEP 2
* During planning consider how often the things are used. * Those you need very often, place near your workstation * Those you need not so often, could be placed slightly away , but they must have proper place.

STEP 3
* Keep a list of things with their locations recorded

HOW DO WE PRACTISE SEISO ?

# Do not wait until things get dirty. # Put aside 3 minutes everyday to clean your workplace. # You and your colleagues should be responsible for the cleaning of the area around your workstation. # Never throw anything around or dirty any place if you can help it. # Do not assume there will be people to clean up mess # SEISO does not only include cleaning your workplace, it includes regular cleaning of machines and tools you use. # Start today. Clean the machines and tools you use. # If you share common machines and tools, take turns or do together.

HOW DO WE PRACTISE SEIKETSU ?

TILL NOW WHAT YOU HAVE DONE IS --- 1S, 2S, 3S
YOU HAVE THROWN AWAY ALL UNNECESSARY ITEMS.
YOU HAVE ARRANGED NECESSARY ITEMS IN GOOD ORDER YOU HAVE CLEANED YOUR WORKPLACE TO MAKE SURE IT IS DUST FREE

NEXT STEP
MAINTAIN ALL THE GOOD WORK DONE TRY TO MAINTAIN THE CLEAN ENVIRONMENT CONSCIOUSLY CREATE A MAINTENANCE SYSTEM FOR HOUSEKEEPING ( MAKE A SCHEDULE FOR CLEANING AND ORGANIZING YOUR WORKPLACE ) CONSIDER HOLDING INTER-DEPARTMENTAL COMPETITIONS ON HOUSEKEEPING

HOW DO WE PRACTISE SHITSUKE ?

* ALWAYS REMEMBER THE VALUE OF YOUR OWN HOUSEKEEPING EFFORTS. * TREAT YOUR WORKPLACE AS YOUR SECOND HOME * TRY TO BE AWARE OF YOUR OWN ATTITUDES AND HABITS. ( YOU MAY UNCONSCIOUSLY DIRTY YOUR WORKPLACE BECAUSE OF LITTLE BAD HABITS)

* SHITSUKE IS MAINLY THE RESPONSIBILITY OF MANAGEMENT. * MANAGEMENT SHOULD TRAIN ITS STAFF AND TRY TO DEVELOP A CULTURE WITHIN THE COMPANY WHEREBY GOOD HOUSEKEEPING BECOMES EVERYBODYS HABIT.

8 CRUCIAL POINTS FOR SUCCESSFUL IMPLEMENTATION OF 5 S

POINT 1 : PARTICIPATION BY ALL PEOPLE POINT 2 : THE PROGRAMME REQUIRES TOP MANAGEMENT COMMITMENT POINT 3 : THE CEO SHOULD TAKE LEADERSHIP OF THE PROGRAMME POINT 4 : THE PROGRAMME SHOULD BE SUPPORTED BY ALL POINT 5 : 5 S PROGRAMME SHOULD BE SELF- SUSTAINING POINT 6 : THE CEO SHOULD MAKE A PERIODIC FACTORY TOUR IN PERSON

POINT 7 : THE PROGRAMME SHOULD GENERATE SUFFICIENT IMPACT AT THE INITIAL STAGE POINT 8 : IMPLEMENTATION OF 5 S SHOULD GO HAND - IN - HAND

5 S IMPLEMENTATION ORGANISATION
5 S ADVISORY COMMITTEE 5 S STEERING COMMITTEE 5 S FACILITATOR 5 S PRACTITIONERS

DIVISION I DIVISION II DIVISION IIII MANAGER MANAGER MANAGER

ALL WORKMEN - 5 S ACTIVITIES

TANGIBLE RESULTS EXPECTED FROM 5 S PRACTICES FROM PEOPLE

1. EMPLOYEES WILL BE DISCIPLINED TO BE MORE AWARE OF UNTIDY WORKPLACES AND MOTIVATED TO IMPROVE THE LEVEL OF CLEANLINESS.
2. GREATER TEAM SPIRIT AND CO-OPERATION CAN BE BUILT UP THROUGH INVOLVEMENT OF ALL WITHIN AN ORGANIZATION. 3. EMPLOYEES WILL BE DISCIPLINED TO FOLLOW SAFER AND BETTER WAYS OF WORK, RESULTING IN LESS RISKS TO ACCIDENTS. 4. EMPLOYEES WOULD BE MORE CONSCIOUS OF IMPROVEMENTS WHICH LEADS TO GREATER EFFICIENCY AND EFFECTIVENESS.

TANGIBLE RESULTS EXPECTED FROM 5 S PRACTISES - FROM MACHINES AND TOOLS 1. MACHINE TROUBLES CAN BE DETECTED AT AN EARLIER STAGE TO PREVENT A MAJOR BREAKDOWN WHEN MACHINES ARE CLEANED DAILY BY PEOPLE OPERATING THEM. 2. DAILY CLEANING OF MEASURING INSTRUMENTS WILL ENSURE ACCURACY AND RELIABILITY.

3. LIFE OF MACHINES AND TOOLS CAN BE EXTENDED SIGNIFICANTLY WHEN THEY ARE HANDLED WITH CARE AND PLACED IN THE DESIGNATED LOCATIONS.

TANGIBLE RESULTS EXPECTED FROM 5S PRACTICES:FROM MATERIALS AND W.I.P

1. FLOW OF MATERIALS AND W.I.P WILL BECOME SMOOTHER.
2. FLOOR SPACE WILL BECOME ORGANIZED AND POSSIBLE AREAS FOR IMPROVEMENT CAN BE EASILY IDENTIFIED BY QUICK OBSERVATION. 3. INVENTORY OF MATERIALS AND W.I.P WILL BECOME CLEARLY VISIBLE AND HANDLED. 4. METERIAL YIELD RATIO CAN BE IMPROVED. 5. REDUCED MATERIAL HANDLING

TANGIBLE RESULTS EXPECTED FROM 5S PRACTICES FROM PRODUCTS AND CUSTOMERS

1. CLEAN WORKPLACE WILL ENSURE THAT FINAL PRODUCTS WILL BE FREE FROM DUST.
2. CLEAN WORKPLACE WILL RESULT IN LOWER DEFECT RATES AND PROMPT EXPOSURE OF QUALITY PROBLEMS.

3. SALES PEOPLE WILL BE EAGER TO SHOW THE CUSTOMERS THE PLANT AND USE IT AS A MARKETING TOOL.